Real-Time Performance Assessment of Process Control in Aluminium Wire Manufacturing Using Siemens S7-1200

Abstract

This paper investigates the real-time performance of process control systems in aluminium (AL) wire manufacturing, with a focus on high-frequency wire drawing operations. A programmable logic controller (PLC)-based control strategy, implemented using the Siemens S7-1200 and integrated with a Human-Machine Interface (HMI), was employed to monitor and manage critical production parameters for the wire tension, drawing speed, motor torque, and dimensional accuracy. Real-time data acquisition enabled continuous performance assessment, fault detection, and immediate corrective action, leading to greater process reliability and efficiency. Experimental results indicate that the integrated system significantly improves product consistency, reduces process variability, and minimises downtime. The findings highlight the importance of real-time monitoring and control in modern wire manufacturing environments and provide a framework for future improvements in smart industrial automation.